products: mounting - mogra small bearings on shaft seats, adapter sleeves or ... for the mounting of...

Products: Mounting

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16 IS 1 Schaeffler Technologies

Page

Products: Mounting

Mechanical mounting anddismounting

Product overview ...................................................................... 18

FeaturesMounting tool sets ............................................................... 20Socket wrenches .................................................................. 21Hook and double hook wrenches.......................................... 22Mechanical extractors .......................................................... 24Hydraulic extractors ............................................................. 26Three-section extraction plates............................................. 27

Hydraulic mounting anddismounting


FeaturesSoftware Mounting Manager................................................. 30Hydraulic nuts...................................................................... 31Pressure generation devices................................................. 33Mobile hydraulic unit ........................................................... 35Hydraulic press .................................................................... 37Connectors, accessories....................................................... 38

Thermal mounting,induction heating devices


FeaturesInduction heating devices HEATER ........................................ 44Accessories.......................................................................... 46FAG Heating Manager ........................................................... 47

Dimension tablesHeating devices HEATER, product range ................................ 48

Thermal mounting anddismounting,

medium frequency technology


FeaturesInduction units with medium frequency technology............... 51

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Schaeffler Technologies IS 1 17

PageMeasurement and inspection Product overview ....................................................................... 58

FeaturesFeeler gauges........................................................................ 60Taper gauges ........................................................................ 60Snap gauges......................................................................... 61Enveloping circle gauges....................................................... 62Visual inspection device ....................................................... 63Axial clearance gauge ........................................................... 63

Accessories Product overview ....................................................................... 64

FeaturesTransport and mounting tool ................................................. 65Mounting paste..................................................................... 66Anti-corrosion oil .................................................................. 66

ST4_27021602377054987_ivz.fm Seite 17 Freitag, 5. Mai 2017 9:24 09


Product overview Mechanical mounting and dismounting

Mounting tool setsSocket wrenches

FITTING-TOOL-ALU-10-50 LOCKNUT-SOCKET

0001

90A1

0001

90A1

000A

32EA

000A

32EA

Hook and double hookwrenches

Hook wrenches

LOCKNUT-HOOK LOCKNUT-HOOK-KM0-16-SET

0001

79C4

0001

79C4

0001

90A3

0001

90A3

Double hook wrenches LOCKNUT-DOUBLEHOOK

0008

AAB3

0008

AAB3

Double hook wrench set LOCKNUT-DOUBLEHOOK-..-SET

0008

9FD

E00

089F

DE

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Mechanical extractorsTwo-arm extractors

Two-arm extractor set

PULLER-2ARM,PULLER-2ARM-SEPARATOR

PULLER-2ARM-SET

0001

90B3

0001

90B3

0001

9328

0001

9328

Three-arm extractors PULLER-3ARM

0001

79C6

0001

79C6

Hydraulic extractors PULLER-HYD

0008

AAD

B00

08AA

DB

Three-sectionextraction plates

PULLER-TRISECTION

0001

7995

0001

7995



Mechanical mounting and dismounting

Features These mechanical tools are designed for the mounting and dismounting of bearings. The mounting forces are transmitted bythe form fit effect.

Mounting tool sets The mounting tool sets are suitable for the simple mounting of rolling bearings with a bore of up to 50 mm, Figure 1. They can also be used for the mounting of sleeves, intermediate rings, seals and similar parts.A mounting tool set contains mounting sleeves made from aluminium and mounting rings made from plastic.

An error frequently made during mounting is to transmit the mounting forces through the rolling elements and raceways.This error can be avoided by driving the inner ring onto the shaft or driving the outer ring into the housing by applying hammer blowsto an appropriate mounting sleeve. The precision parts are matched to each other, ensuring that the forces are uniformly transmittedto the end faces of the bearing rings.

Scope of delivery

Ordering designation FITTING-TOOL-ALU-10-50Also available as individual parts.

Further information ■ TPI 216, Tools for the Mechanical Mounting andDismounting of Rolling Bearings

■ Enquiries:[email protected], +49 2407 9149-66.

Figure 1Mounting tool set 00

01A4

8500

01A4

85

Mounting tool set comprising 33 mounting rings for bearing bore 10 mm to 50 mm and outside diameter up to 110 mm3 mounting sleeves1 recoilless hammer, mass 1 kg1 case

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Socket wrenches Socket wrenches LOCKNUT-SOCKET are suitable for the simple tightening and loosening of locknuts on shafts, adapter sleeves and withdrawal sleeves. They require less space on the circumference of the nut than hook wrenches and allow the use of ratchets and torque wrenches, Figure 2.

For increased reliability, socket wrenches should be secured usinga locking pin and rubber ring. They therefore have a hole forthe locking pin and a groove for the rubber ring. The locking pin and rubber ring are included in the scope of delivery.Socket wrenches are available in sizes suitable for locknuts KM0 to KM20. Other sizes and special solutions are available by agreement.

Scope of delivery

Ordering example Socket wrench, suitable for locknut KM5Ordering designation LOCKNUT-SOCKET-KM5

Special sizes available by agreement.



Figure 2Socket wrench and torque wrench 00

095A

6700

095A

67

1 socket wrench1 locking pin1 rubber ring




Hook and double hookwrenches

These wrenches are used to move locknuts or extraction nutsfor the mounting or dismounting of rolling bearings or withdrawal sleeves.

Hook wrenches A hook wrench LOCKNUT-HOOK can be used to dismount not only bearings but also withdrawal sleeves with the aid of extraction nuts.Hook wrenches are available in sizes suitable for locknuts KM0 to KM40, suitable for diameters from 16 mm to 245 mm.

Ordering example Hook wrench, suitable for locknuts KM18, KM19 and KM20Ordering designation LOCKNUT-HOOK-KM18-20

These wrenches can be used for the mounting and dismountingof small bearings on shaft seats, adapter sleeves or withdrawal sleeves. In addition to the sizes stated here, other sizes are available by agreement.

Ordering example Set comprising ten hook wrenchesOrdering designation LOCKNUT-HOOK-KM0-16-SET

Hook wrenches can also be ordered as a set. The set comprisesten hook wrenches of sizes KM0 to KM16 in a roll-up pouch and is suitable for diameters from 16 mm to 100 mm.

Double hook wrenches Double hook wrenches LOCKNUT-DOUBLEHOOK are intendedfor the mounting of spherical roller bearings and self-aligning ball bearings with a tapered bore, Figure 3. The individual wrenchesare available as a set.

Figure 3Double hook wrenches 00

097B

1D00

097B

1D



The double hook wrench sets contain a torque wrench. This allowsa precisely defined tightening torque to be achieved at the startof the mounting operation.Double hook wrench sets are suitable for several sizes of locknuts. There is one set each for locknuts KM3 to KM8 and for locknuts KM9 to KM15. All the parts in the scope of delivery are also availableindividually.Each double hook wrench is engraved with the torsion anglesfor the appropriate spherical roller bearings and self-aligning ball bearings. The drive-up distance and reduction in radial internal clearance can thus be precisely set.

Scope of delivery

Ordering example 4 double hook wrenches, suitable for locknuts KM3 to KM8Ordering designation LOCKNUT-DOUBLEHOOK-KM3-8-SET

Ordering example 5 double hook wrenches, suitable for locknuts KM9 to KM15Ordering designation LOCKNUT-DOUBLEHOOK-KM9-15-SET

Several double hook wrenches1 torque wrench1 mounting lever1 user manual1 case1 mounting paste (20 g)




Mechanical extractors Mechanical extractors can be used to dismount small and medium sized rolling bearings that are located with a tight fit on a shaft orin a housing. The bearing can be dismounted without damageif the extractor is in contact with the tightly fitted bearing ring.In the case of mechanical extractors, the extraction force is normally applied by means of threaded spindles.In addition to the two-arm and three-arm devices as well asa hydraulic pressure tool, special solutions are also possible.For the dismounting of larger bearings, hydraulic extractors should be used, see page 26.

Two-arm and three-arm extractors Two-arm and three-arm extractors, Figure 4, Figure 5 and tables, page 25, are used for the extraction of complete rolling bearings or tightly fitted inner rings.The two-arm extractor PULLER-2ARM and three-arm extractor PULLER-3ARM can also be used to extract other parts such as gears.

Figure 4Two-arm extractor,

dimensions of gripper 000A

4B9C

000A

4B9C

Figure 5Three-arm extractor,

dimensions of gripper 000A

4BB5

000A

4BB5



Available two-arm extractors

Available two-arm extractor set

Available three-arm extractors



Designation Grip span

Grip depth

Dimensions Extrac-tion forcew t a b

mm mm mm mm kN

PULLER-2ARM90 90 100 15 22 30

PULLER-2ARM130 130 100 15 22 30

PULLER-2ARM160 160 150 24 30 50

PULLER-2ARM200 200 150 24 30 50

PULLER-2ARM250 250 200 32 36 75

PULLER-2ARM350 350 200 32 36 75

PULLER-2ARM-SEPARATOR45 45 65 2,5 12+1 10



Designation: PULLER-2ARM-SETTwo-arm extractors included

PULLER-2ARM130, PULLER-2ARM200, PULLER-2ARM350Accessories included

Narrow extraction hook for size 130 and 200, tube of spindle grease,carry case

Designation Grip span

Grip depth

Dimensions Extrac-tion forcew t a b

mm mm mm mm kN

PULLER-3ARM160 160 100 14+1 15+1 45

PULLER-3ARM230 230 165 19+1 22+1 100

PULLER-3ARM310 310 235 19+1 22+1 100

PULLER-3ARM430 430 240 20+2 30+2 150

PULLER-3ARM660 660 340 22+2 34+2 150




Hydraulic extractors Hydraulic extractors, see tables, are used where higher extraction forces are required.These devices allow rolling bearings, gears, sleeves and many other shrink fitted parts to be quickly and easily dismounted.For larger grip depths, the XL design or longer extraction arms are available as accessories.Operating personnel can be protected by means of a safety grid ora safety cover.The advantageous features of hydraulic extractors are as follows:■ parts under mechanical load made from high quality chromium-

molybdenum steel■ smooth-running, chromium plated piston made from hardened

and tempered steel■ stroke travel adjustable by means of standard adapter■ screw thread for setting of optimum grip depth ■ simple centring by spring-loaded steel cone■ simple conversion to two-arm operation in case of insufficient

space for three arms■ optimum operating position due to rotatable pump hand lever or

separate pump.

Available hydraulic extractorswith integral hand pump

Available hydraulic extractorswith separate hand pump



Designation Extrac-tion force

Grip span Grip depth Stroke lengthStandard XL Standard XL

kN mm mm mm mm mm

PULLER-HYD40 40 200 – 165 – 55

PULLER-HYD60(-XL) 60 200 260 165 210 82

PULLER-HYD80(-XL) 80 260 300 210 240 82

PULLER-HYD100(-XL) 100 250 280 185 210 82

PULLER-HYD120(-XL) 120 300 330 240 280 82

PULLER-HYD200(-XL) 200 360 380 275 330 82

PULLER-HYD250(-XL) 250 410 440 315 380 110

PULLER-HYD300(-XL) 300 540 540 405 610 110

Designation Extrac-tion force

Grip span Grip depth Stroke lengthStandard XL Standard XL

kN mm mm mm mm mm

PULLER-HYD400(-XL) 400 580 1 000 420 635 125



Three-sectionextraction plates

Three-section extraction plates PULLER-TRISECTION, see table,can be used with hydraulic and mechanical extractors.These allow the extraction of complete bearings, tightly fitted inner rings and other components.The load carrying capacity is matched to the maximum extraction force of the hydraulic extractors used in each case. In order to prevent damage to the bearing during extraction, the geometrical form of the three extraction segments means that they gripthe bearing on the inner ring only.The extraction plates can be fitted under the bearing with just a few movements.

Available three-sectionextraction plates

1) dmin and dmax, Figure 6.



Figure 6Maximum and minimum diameter

of extraction plates, see table 0001

9341

0001

9341

Designation Dimensions Recommended for extractor

dmin1) dmax

1) PULLER-HYD PULLER-3ARMmm mm

PULLER-TRISECTION-50 12 50 – 160

PULLER-TRISECTION-100 26 100 40, 60, 80, 100 230

PULLER-TRISECTION-160 50 160 80, 100, 120, 175, 200

310

PULLER-TRISECTION-260 90 260 175, 200, 250, 300 430

PULLER-TRISECTION-380 140 380 250, 300, 400 660



Product overview Hydraulic mounting and dismounting

Hydraulic nuts HYDNUT

000A

0428

000A

0428

Hand pumpsSingle stage

PUMP1000-0,7L

0008

9FF1

0008

9FF1

Twin stage PUMP1000-4L, PUMP1000-8L, PUMP1600-4L, PUMP1600-8L, PUMP2500-4L, PUMP2500-8L

0008

A00C

0008

A00C

Mobile hydraulic unitTool set

TOOL-RAILWAY-AGGREGATE TOOL-RAILWAY-AXLE

0008

A039

0008

A039

0001

9EB6

0001

9EB6



Hydraulic pressSealing cap tool

TOOL-RAILWAY-SEALCAP-PRESS

TOOL-RAILWAY-SEALCAP

000A

37B8

000A

37B8

000A

37BD

000A

37BD

Connectors, accessoriesAdapters and reduction nipples

Rapid push fit coupling

PUMP.NIPPLE,PUMP.ADAPTER

PUMP1600.VALVE-NIPPLE,PUMP1600.VALVE-SOCKET

0001

79C3

0001

79C3

0001

9DD

B00

019D

DB

Digital manometerManometer

PUMP1000.MANO-DIGI PUMP1000.MANO-G1/2,PUMP1600.MANO-G1/2

0001

79BD

0001

79BD

0001

79B5

0001

79B5

Sleeve connector PUMP.SLEEVE-CONNECTOR

0001

7AC7

0001

7AC7



Hydraulic mounting and dismounting

Features Hydraulic tools can be used to apply large forces. These tools are therefore particularly suitable for the mounting and dismountingof large bearings or parts with a tapered bore. Hydraulic nuts are used as a mounting tool. Pressure can be generated using hand pumps.

SoftwareMounting Manager

The program Mounting Manager gives assistance in selectingthe correct mounting of bearings and offers the following options:■ It shows various mechanical and hydraulic mounting methods.■ It calculates the data required for mounting in relation to

reduction in radial internal clearance, drive-up distance andstart pressure.

■ It gives advice on mounting.■ It generates a list of the accessories and tools required.It also contains a library with references to publications giving further information and an electronic learning system.The program Mounting Manager is available online athttp://mountingmanager.schaeffler.com/startApp.do

Mounting method Bearings with a tapered bore are mounted either directly on the tapered shaft or journal or by means of an adapter sleeve or with-drawal sleeve on the cylindrical shaft. The internal clearance is set either by measurement of the axial drive-up distance or by conven-tional means using feeler gauges.

Measurementof the axial drive-up distance

For measurement of the drive-up distance, a dial gauge is screwed into the hydraulic nut. The dial gauge is preloaded and the measure-ment sensor then precisely follows the displacement of the press ring. This value corresponds to the displacement of the rolling bearing on the tapered seat.

Measurement of the reductionin radial internal clearance

When the bearing is driven onto the tapered seat, the inner ring is expanded and the radial internal clearance is thereby reduced.This reduction in radial internal clearance is an indication of the tight fit of the bearing. Measurement is carried out using a feeler gauge.



Hydraulic nuts Hydraulic nuts HYDNUT, Figure 1 and table, are used to press components with a tapered bore onto their tapered seat. Presses are mainly used if the drive-up forces required cannot be applied using other accessories, e.g. shaft nuts or pressure screws.

The main applications are as follows:■ Rolling bearings with a tapered bore can be mounted and

dismounted.Bearings can be seated directly on a tapered shaft, an adapter sleeve or a withdrawal sleeve. The hydraulic nut can also be used for the dismounting of adapter or withdrawal sleeves.

■ Components such as couplings, gears and ships’ propellers can be mounted and dismounted.

Available hydraulic nuts

Figure 1Hydraulic nut with dial gauge 00

0A04

3A00

0A04

3A

Designation Design Application

HYDNUT50..-E to HYDNUT200..-E

With metric fine pitch threadto DIN 13

Standardised adapter and withdrawal sleeves

HYDNUT205..-E to HYDNUT1180..-E

With trapezoidal threadto DIN 103

With metric dimensions

HYDNUT90-E-INCH to HYDNUT530-E-INCH

With inch size thread to ABMA “Standards for Mounting Accessories, Section 8, Locknut Series N-00”

Sleeves with inch dimensions

HYDNUT100-HEAVY to HYDNUT900-HEAVY

Increased capacity designwith smooth bore

For high mounting forces, for examplein shipbuilding




Scope of delivery The scope of delivery comprises the hydraulic nut, accessories and user manual, Figure 2.

Scope of delivery

Ordering designation HYDNUT

Further information ■ TPI 196, FAG Hydraulic Nuts■ Enquiries:

[email protected], +49 2407 9149-66.

� Hydraulic nut� Knurled screws

� Screw plug� Grub screws

� Hand lever� Connection nipple

� Replacement seals and red ring User manual

Figure 2Scope of delivery

Hydraulic nut 0009

E443

0009

E443

1 hydraulic nut2 replacement seals1 red ring1 screw plug3/5 grub screws1 connection nipple3 knurled screws1 hand lever1 user manual



Pressure generation devices Pressure generation devices are available in various designs:from the hand pump via the mobile hydraulic unit to the hydraulic press, see tables.

ApplicationHand pump

ApplicationMobile hydraulic unit

ApplicationHydraulic press

Further information ■ TPI 195, FAG Pressure Generation Devices.

Designation Application

PUMP1000-0,7L ■ Mounting and dismounting of rolling bearings

■ For driving hydraulic nutsup to HYDNUT395 or HYDNUT300-HEAVY

PUMP1000-4L ■ Mounting and dismounting of rolling bearings

■ Mounting and dismountingof components such as ships’ propellers

■ For driving hydraulic nutsup to HYDNUT800

PUMP1600-4L ■ Mounting and dismounting of rolling bearings

■ Mounting and dismountingof components such as rudder splines and rudder blades

PUMP2500-4L ■ Mounting and dismounting of bearings■ Mounting and dismounting

of components such as gears and couplings


TOOL-RAILWAY-AGGREGATE ■ Mounting and dismounting of tapered roller bearing units (TAROL)


TOOL-RAILWAY-SEALCAP-PRESS ■ Mounting and dismounting of sealson tapered roller bearing units (TAROL)




Hand pumps Hand pumps have a single stage or twin stage pump witha manometer.

Single stage pump The hand pump PUMP1000-0,7L has an oil container with a volume of 0,7 l. The maximum oil pressure is 1 000 bar, see table.A digital manometer is available as an accessory.

Available single stage pump

Twin stage pump The twin stage pumps, Figure 3 and table, have a high delivery rate up to 50 bar and then switch automatically to the high pressure stage. This gives a high work rate.

Where there is an increased oil requirement, the twin stage pumps are available with an 8-l oil container (suffix 8L). If the type of mounting of the adapter or withdrawal sleeve requires a separate oil supply, a two-way valve is available (suffix D).For pumps with an oil pressure of 1 000 bar and a connector, digital manometers are also available as accessories.

Available twin stage pumps

Designation Maximum oil pressurebar

PUMP1000-0,7L 1 000

Figure 3Twin stage pump,

4-l oil container 0008

A05E

0008

A05E

Designation Maximum oil pressurebar

PUMP1000-4L 1 000

PUMP1600-4L 1 600

PUMP2500-4L 2 500



Mobile hydraulic unit The mobile hydraulic unit, Figure 4, is used for the mounting and dismounting of tapered roller bearing units, also known as TAROL units. These units are used as wheelset bearings in rail vehicles such as goods wagons and passenger carriages.The mobile unit has a valve-controlled, double direction pressure cylinder driven by a motor pump. The pressure cylinder is adjustable in height.When making enquiries or placing orders, information on the power connection is required.

Ordering designation TOOL-RAILWAY-AGGREGATE

Figure 4Mobile hydraulic unit 00

017A

5100

017A

51




Tool set Tool sets are produced for a specific application, Figure 5. When making enquiries or placing orders, information on the bearing type and installation drawings (shaft, housing, additional parts) are required.

Ordering designation TOOL-RAILWAY-AXLE

Figure 5Tool set 00

019F

0C00

019F

0C



Hydraulic press The hydraulic press, Figure 6, is used for the mounting and dis-mounting of seals on tapered roller bearing units, also known as TAROL units. In addition, a matching tool set is required for each bearing type.

Ordering designation TOOL-RAILWAY-SEALCAP-PRESS

Sealing cap tool Sealing cap tools are bearing-specific and include all the partsfor mounting and dismounting of the seal. For dismounting, the parts required are an adapter ring, a punch and the appropriate press-out segments. For mounting of the new seal, a support and the appropriate press-in ring are supplied.

Ordering designation TOOL-RAILWAY-SEALCAP

Further information ■ TPI 195, FAG Pressure Generation Devices■ TPI 156, Tapered Roller Bearing Units TAROL –

Mounting, Maintenance, Repair■ Enquiries:

[email protected], +49 2407 9149-66.

Figure 6Hydraulic press 00

0A39

9900

0A39

99




Connectors, accessories Various connectors and accessories are available for use withthe devices for hydraulic mounting and dismounting.

Adapters and reduction nipples Adapters and reduction nipples are matched to the threads of high pressure hoses and pipes, Figure 7 and tables.Adapters and reduction nipples of type A (with sealing ring) are suitable for oil pressures up to 800 bar, Figure 7. Type B (with blade sealing) is suitable for oil pressures up to 2 500 bar, Figure 7.

Available adapters andreduction nipples

Available adapters

� Type A� Type B

Figure 7Adapters and reduction nipples 00

017A

0300

017A

03

Designation Designation

PUMP.NIPPLE-A-G1/4-G1/8 PUMP.NIPPLE-A-G3/4-G1/8PUMP.NIPPLE-B-G1/4-G1/8 PUMP.NIPPLE-B-G3/4-G1/8PUMP.NIPPLE-A-G1/4-G1/2 PUMP.NIPPLE-A-G3/4-G1/4PUMP.NIPPLE-B-G1/4-G1/2 PUMP.NIPPLE-B-G3/4-G1/4PUMP.NIPPLE-A-G1/4-G3/4 PUMP.NIPPLE-A-G3/4-G3/8PUMP.NIPPLE-B-G1/4-G3/4 PUMP.NIPPLE-B-G3/4-G3/8PUMP.NIPPLE-A-G1/4-M14 PUMP.NIPPLE-A-M18�1,5-G1/4PUMP.NIPPLE-B-G1/4-M14 PUMP.NIPPLE-A-M18�1,5-G3/8PUMP.NIPPLE-A-G1/4-M18�1,5 PUMP.NIPPLE-A-M18�1,5-G3/8PUMP.NIPPLE-A-G3/8-G1/4 –

PUMP.NIPPLE-B-G3/8-G1/4 –

Designation Designation

PUMP.ADAPTER-A-G1/4 PUMP.ADAPTER-A-G3/4PUMP.ADAPTER-B-G1/4 PUMP.ADAPTER-B-G3/4



Rapid push fit coupling A suitable connecting nipple is always included in the delivery ofa hydraulic nut. Each hand pump with an oil pressure up to 1600 bar is supplied with a rapid push fit coupling. The rapid push fit coupling allows rapid connection and disconnection of a hose and is suitable for oil pressures up to 1600 bar, Figure 8 and table.After the coupling has been fitted, the high pressure hose must be secured to the connection point by means of a chain or cord.

Available nipple and socket

� Nipple� Socket

Figure 8Rapid push fit coupling 00

019D

D9

0001

9DD

9

Designation Threaded connector

Component

inch

PUMP1600.VALVE-NIPPLE G1/4 Nipple

PUMP1600.VALVE-SOCKET G1/4 Socket




Manometer In addition to the manometer with digital display, there are three analogue manometers with an indicator, see table.When selecting a manometer, pay attention to the maximum oil pressure.

Available manometers

Sleeve connectors Sleeve connectors can be used at pressures up to 800 bar.The connector to the pump holder is G1/4. The connector tothe consumer device is available in the sizes M6, M8, G1/8 and G1/4. For other thread sizes, a reduction nipple can be used.Check the oil pressure using a manometer.

Ordering example Sleeve connector with a connector G1/8 on the consumer device sideOrdering designation PUMP.SLEEVE-CONNECTOR-G1/8

Designation Threaded connector

Maximumoil pressure

inch bar

PUMP1000.MANO-DIGI G1/4 1 000

PUMP1000.MANO-G1/2 G1/2 1 000

PUMP1600.MANO-G1/2 G1/2 1 600



Product overview Thermal mounting, induction heating devices

Tabletop devices HEATER50 HEATER100

HEATER200

0009

DF3

400

09D

F34

0009

DF4

300

09D

F43

0009

DF5

500

09D

F55



Standalone devices HEATER400

HEATER800

HEATER1600

0009

DF6

D00

09D

F6D

0009

DF6

600

09D

F66

0009

DF5

C00

09D

F5C



Thermal mounting, induction heating devices

Features Induction heating devices HEATER with mains frequency technology are used to heat rolling bearings and other components witha cylindrical bore where a tight fit on the shaft or in the housing is intended.Adequate expansion of the bearings is achieved in most cases at +80 °C to +100 °C. During the heating operation, the maximum heating temperature must be observed. The temperature of rolling bearings must not normally exceed +120 °C, in order to prevent changes to the structure and hardness of the bearing. In all devices for heating, the temperature can be steplessly controlled.Wear protective gloves during mounting and dismounting of heated parts.

Induction heating devicesHEATER

The induction heating devices HEATER for rolling bearings up toa mass of 1600 kg have been improved further in terms of their per-formance capability and safety compared with their predecessors. They can also be used to heat sealed and greased rolling bearings. In addition to the tabletop devices HEATER50 to HEATER200,the range also includes the standalone devices HEATER400 to HEATER1600 for larger rolling bearings.The scope of delivery of the induction heating devices HEATER covers a basic setup, Figure 1.

� Heating device� Slewing ledge

� Temperature sensor� Lifting tool

� User manual

Figure 1Scope of delivery

Heating device HEATER200 0009

CF94

0009

CF94



The rolling bearing to be heated is either suspended from the ledge or is laid horizontally on the sliding table, Figure 2.

Advantages of FAG heating devices The advantages of the induction heating devices are:■ very safe operation■ high reliability (TÜV certified)■ effective, energy-efficient heating (high efficiency level)■ uniform, controlled heating■ automatic demagnetisation■ simple operation■ high cost-effectiveness through selection of the device size most

suitable for the particular application.

Operating modes The induction heating devices can be operated in the following modes:■ temperature control■ time control■ ramp control■ delta-T control.

� Slewing ledge� U-shaped core� Rolling bearing

� Sliding table

Figure 2Heating of rolling bearing 00

09D

D1A

0009

DD

1A



Thermal mounting, induction heating devices

Accessories The functional scope of an induction heating device can be extended by the use of accessories.

Temperature sensor Two temperature sensors can be connected to each induction heating device. The sensor head of the temperature sensor is magnetic and is positioned on the component. The signal is fedvia the cable and plug to the device, Figure 3.The induction heating devices HEATER50 and HEATER100 are supplied with one temperature sensor. If two temperature sensors are used, it is possible to operate the heating method with delta-T control.

Ledge Each induction heating device is supplied with one ledge.This ledge has the same cross-section as the U-shaped core and allows maximum power to be achieved.In order to heat rolling bearings of a smaller inside diameter, ledges with smaller cross-sections are available.

Adapter posts For the tabletop devices HEATER50, HEATER100 and HEATER200, adapter posts are available. These are always placed in pairs onthe U-shaped core and thus increase the inner height. With the aid of adapter posts, it is also possible to heat workpieces with a small inside diameter and a large outside diameter.

Further information ■ TPI 200, FAG Heating Devices for the Mounting of Rolling Bearings■ Enquiries:

[email protected], +49 2407 9149-66.

� Sensor head� Cable

� Plug

Figure 3Temperature sensor 00

0A4D

A100

0A4D

A1



FAG Heating Manager The software FAG Heating Manager is a user-friendly tool for selection of the optimum heating device for the heating of rolling bearings.Once the rolling bearing to be heated has been selected, the bearing type, dimensions, mass and the suitable heating device are displayed, Figure 4.

The FAG Heating Manager is available online at www.schaeffler.de, menu item Mediathek.

Figure 4FAG Heating Manager 00

0A40

0E00

0A40

0E



Heating devices HEATERProduct range

1) When using the ledge included in the scope of delivery.

Dimension table

Characteristics Unit HEATER50

Operating voltage U VAC 110 to 230

Frequency F Hz 50 to 60

Power consumption P kVA 3

Current rating I A 13

Residual magnetism H A/cm � 2

Operating duration ED % 100

Mass m kg 18

Length L mm 450

Width B mm 210

Height H mm 250

Dimension a mm 120

Dimension b mm 140

Maximum rolling bearing mass m kg 50

Maximum mass of other component m kg 40

Maximum width b mm 120

Minimum inside diameter 1) d mm 55

Minimum inside diameter with accessories d mm 10

Maximum inside diameter (lying flat) d mm 300

Maximum outside diameter D mm 400(with LEDGE-55)

ST4_27021604951446795_heater50.fm Seite 48 Freitag, 5. Mai 2017 9:37 09


HEATER100 HEATER200 HEATER400 HEATER800 HEATER1600

110 to 230 400 to 480 400 to 480 400 to 480 400 to 480

50 to 60 50 to 60 50 to 60 50 to 60 50 to 60

3,7 8 12,8 25,2 40

16 20 32 63 100

� 2 � 2 � 2 � 2 � 2

100 100 100 100 100

35 86 157 280 650

540 695 850 1 080 1 500

275 330 420 500 800

310 370 950 1 250 1 600

180 210 300 430 690

180 210 330 490 700

100 200 400 800 1 600

80 150 300 600 1 200

180 210 330 400 650

70 100 120 150 220

15 20 35 50 90

400 500 900 1 400 1 900

500(with LEDGE-70)

600(with LEDGE-100)

1 000(with LEDGE-120)



ST4_27021604951446795_heater50.fm Seite 49 Freitag, 5. Mai 2017 9:37 09


Product overview Thermal mounting and dismounting, medium frequency technology

Medium frequency technology HEAT-INDUCTOR, HEAT-GENERATOR

HEAT-INDUCTOR

000A

044C

000A

044C

000A

045E

000A

045E



Thermal mounting and dismounting, medium frequency technology

Features Induction units based on medium frequency technology are,in contrast to induction heating devices, suitable not only for thermal mounting but also for dismounting. Furthermore, they can be used for the heating of very large and heavy components.Adequate expansion of the bearings is achieved in most casesat +80 °C to +100 °C. During the heating operation, the maximum heating temperature must be observed. The temperature of rolling bearings must not normally exceed +120 °C, in order to prevent changes to the structure and hardness of the bearing. In all devices for heating, the temperature can be steplessly controlled.Wear protective gloves during mounting and dismounting of heated parts.

Induction units withmedium frequency technology

Due to their high flexibility and compact construction, these units can also be used for mobile operation. They can therefore be used, for example, at construction sites for wind turbines or for other large components that are difficult to transport.

Application Examples of the use of medium frequency technology include:■ heating of medium-sized to large bearings for mounting and

dismounting■ heating of housings prior to mounting of a bearing■ batch dismounting of bearing inner rings of cylindrical roller

bearings and labyrinth rings, for example in the case of wheelset bearings in rail vehicles

■ dismounting of bearing inner rings from traction motors in rail vehicles

■ heating of large components, for example bearings or machine supports in wind turbines

■ heating of roll rings and couplings, for example in steelworks■ loosening of shrink fit connections of gears.




The units comprise a generator and an inductor that is positionedon the workpiece. Depending on the requirements, a rigid or flexible inductor is used. Depending on the application, flexible inductors are positioned in the bore or on the outside diameter of the work-piece, Figure 1. Flexible inductors are suitable for the heating of bearing inner rings or of large components such as machine sup-ports in wind turbines. The length of the inductor is defined asa function of the dimensions of the workpiece.

Flexible inductors The flexible inductors are available in two designs that differ mainly in their geometrical characteristics but also in their maximum operating duration, see table.

Technical dataon flexible inductors

Figure 1The flexible inductor can be

wrapped around the component

000A

0470

000A

0470

Designation Inductor HEAT-INDUCTOR

-..M-D15 -..M

Cooling system – Air cooling

Length m 12 – 16 12 – 40

Diameter mm approx. 18 approx. 20

Minimum bending radius mm 80 150

Mass without plug kg/m approx. 0,6 approx. 1

Permissible temperature of work-piece surface

°C +180

Maximum temperature atpush fit connector

°C +90

Maximum operating duration – � 10 min �

Connection of inductor and generator

– Push fit connector



The flexible inductors are available in various lengths, see table.

Ordering designations and lengths

Rigid inductors Rigid inductors are particularly suitable for batch production, Figure 2. In such cases, the emphasis is less on flexibility and more on short set-up times and high process reliability.

Ordering designation Lengthm

HEAT-INDUCTOR-12M-D15 12



HEAT-INDUCTOR-12M 12







Figure 2Rigid inductor for dismounting

of wheelset bearings

000A

3305

000A

3305




Generators Compared with preceding models, the generators are of a signifi-cantly more compact and lighter design and are thus even more suitable for mobile operation. They are available in two performance variants and two voltage versions, Figure 3 and tables, page 55.

Technical data of generatorswith voltage rating of 400 V

1) Valid for voltage rating of 400 V.

Figure 3Generators 00

0A04

8200

0A04

82

Designation Generator HEAT-GENERATOR

20-2 40-2

Cooling – Open circuit ventilation

Mains voltage V 3�380 – 3�440

Mains frequency Hz 50 – 60

Voltage tolerance – �10%

Connector plug CEE A 32 63

Line-side fuse protection A 32 63

Effective power kW 201) 401)

Output frequency kHz 10 – 25

Length of mains connection cable m 5

Width mm 277 365

Depth (with mains connection cable)

mm 610

Height (with grips) mm 540 695

Mass kg 30 55



Technical data of generatorswith voltage rating of 480 V

1) Valid for voltage rating of 480 V.

Digital control Digital control is carried out by means of a 7� TFT display and hasthe following characteristics:■ presentation of temperature patterns on the display■ storage and export of temperature patterns by means of

an integrated temperature recorder■ separate registration for operator and service operator,

with different access rights■ alarm functions for protection of the workpiece against

overheating– temperature increase alert– temperature alarm on overshoot

■ user languages: German and English■ remote access possible via an Ethernet interface.

Designation Generator HEAT-GENERATOR

20-2-480V 40-2-480V

Cooling – Open circuit ventilation

Mains voltage V 3�460 – 3�500

Mains frequency Hz 50 – 60

Voltage tolerance – �10%

Connector plug CEE A 32 63

Line-side fuse protection A 32 63

Effective power kW 201) 401)

Output frequency kHz 10 – 25

Length of mains connection cable m 5

Width mm 277 365

Depth (with mains connection cable)

mm 610

Height (with grips) mm 540 695

Mass kg 30 55




Advantages The advantages of the heating device with medium frequency technology are as follows:■ suitable for mounting■ suitable for dismounting■ operating frequency from 10 kHz to 25 kHz■ efficiency of the generator higher than 90%■ low energy requirements■ short heating times■ time and temperature control as well as other operating modes■ automatic demagnetisation■ flexible and rigid inductors available■ inductors suitable for use either inside or outside the component■ lower mains connection power than heating devices with mains

frequency■ almost silent■ air-cooled system.

Configuration Each of the light and compact devices is designed for the specific application. It can be equipped, depending on the workpiece,with flexible or rigid inductors.For enquiries, the following data are required:■ bearing dimensions, if possible with drawings■ representation of the adjacent construction■ data on the fit conditions■ description of the mounting process and its frequency■ power supply data■ ambient conditions■ your address.

Further information ■ TPI 217, Induction Units with Medium Frequency Technology■ Enquiries:

[email protected], +49 2407 9149-66.



Product overview Measurement and inspection

Feeler gauges FEELER-GAUGE-100,FEELER-GAUGE-300

0001

79A9

0001

79A9

Taper gauges MGK133 MGK132

0001

79BA

0001

79BA

0001

79BB

0001

79BB

Snap gauges SNAP-GAUGE

0001

79A7

0001

79A7

Enveloping circle gauges MGI21 MGA31

0001

79A5

0001

79A5

0001

79A6

0001

79A6

ST4_9007203874030731_produktue.fm Seite 58 Freitag, 5. Mai 2017 9:40 09


Visual inspection device TOOL-RAILWAY-INSPECTION-DEVICE

000A

32C6

000A

32C6

Axial clearance gaugeAdapter set

TOOL-RAILWAY-CLEARANCE-BASIC

TOOL-RAILWAY-CLEARANCE.TOP

000A

33BA

000A

33BA

000A

3990

000A

3990

ST4_9007203874030731_produktue.fm Seite 59 Freitag, 5. Mai 2017 9:43 09


Measurement and inspection

Features Feeler gauges and measurement gauges can be used to checkthe production of bearing seats and the mounting of bearings.

Feeler gauges Feeler gauges FEELER GAUGE, see table, are used to measurethe radial internal clearance, especially in mounting on tapered shaft seats and on adapter and withdrawal sleeves.

Available feeler gauges

Taper gauges These gauges are used to inspect tapered bearing seats in pro-duction facilities. This is necessary to ensure a good match between the fit surfaces of the bearing and bearing seat. Gauges are available for different taper angles.

Taper gaugefor taper 1:12 and 1:30

The taper gauge MGK133 is used for the measurement of external tapers 1:12 and 1:30 with a taper diameter of 27 mm to 205 mm.The reproducibility of the measurement results is less than 1 �m.The gauge rests on the workpiece with four hardened and polished pins. The position of the gauge on the taper is defined by thesepins and a stop. The stop can be attached to either the front or backof the gauge.The gauge has two movable measuring brackets. One of theseis in contact with the small taper diameter, the other with the large taper diameter. There is a fixed spacing between the measuring brackets. The deviation of the taper diameter from the nominal value is displayed in both measurement planes by a precision indicator.The gauge is set using a reference taper (available by agreement).

Ordering designation Available by agreement

Designation Feeler length

Feeler thickness

mm mm

FEELER-GAUGE-100 100 0,03 0,08 0,14

0,04 0,09 0,16

0,05 0,1 0,18

0,06 0,12 0,2

0,07 – –

FEELER-GAUGE-300 300 0,03 0,12 0,2

0,04 0,13 0,25

0,05 0,14 0,3

0,06 0,15 0,35

0,07 0,16 0,4

0,08 0,17 0,45

0,09 0,18 0,5

0,1 0,19 –



Taper gaugefor taper angle 0° to 6°

The taper gauge MGK132 is used for the measurement of external tapers with a taper angle of 0° to 6° and a taper diameter of 90 mm to 360 mm.The reproducibility of the measurement results is less than 1 �m.The gauge rests on the workpiece with four hardened, ground and lapped ledges. The ledges form an angle of 90°. The positionof the gauge on the taper is defined by a stop on the front or backof the gauge.The measurement slide runs between the support ledges. A dial gauge in the housing acts against the measurement slide anddisplays the deviation of the taper diameter from the nominal value. The deviation of the taper from the nominal value is displayedby a precision indicator on the measurement slide.The gauge is set using a reference taper (available by agreement).

Ordering designation Available by agreement

Snap gauges Snap gauges SNAP GAUGE, see table, can be used to checkthe diameter of cylindrical workpieces directly on the machine tool. The snap gauge is also used to set the enveloping circle gauge MGI21.The snap gauge functions as a comparator gauge. It is set using shims. The deviation from the set value can then be determined.

Available snap gauges

Shims for numerous diameters are available as accessories.

Ordering example Snap gauge for shaft diameter 120 mmOrdering designation SNAP-GAUGE-100/150

Ordering example Shim for shaft diameter 120 mmOrdering designation SNAP-GAUGE.MASTER120

Designation Diameter range

min. max.mm mm

SNAP-GAUGE-30/60 30 60

SNAP-GAUGE-60/100 60 100

SNAP-GAUGE-100/150 100 150

SNAP-GAUGE-150/200 150 200

SNAP-GAUGE-200/250 200 250

SNAP-GAUGE-250/300 250 300



Measurement and inspection

Enveloping circle gauges Enveloping circle gauges, see table, can be used to set the radial internal clearance or preload of cylindrical roller bearings.

Available enveloping circle gauges

Bearings with separable inner rings The enveloping circle gauge MGI21 is used to measure, by meansof two hardened and precision ground surfaces, the internal enveloping circle of a roller and cage assembly. One measurement surface is movable.Before measurement, the gauge is set to the internal enveloping circle of the roller and cage assembly. This setting operation requires a snap gauge such as SNAP GAUGE.After mounting of the outer ring together with the roller and cage assembly, the enveloping circle diameter is then determined using the gauge MGI in a comparative measurement.In the case of a bearing with a tapered bore, the enveloping circle measurement is used to calculate its position on the tapered seatof the shaft. During mounting, the bearing is driven to this position. This results in the internal clearance or the preload.In the case of bearings with a cylindrical bore, preground inner rings (suffix F12) are used and are finish ground to the required bearing diameter.

Ordering example Enveloping circle gauge for cylindrical roller bearings NNU4920Ordering designation MGI21-NNU4920

Bearings with separable outer rings The enveloping circle gauge MGA31 is used to measure, by meansof two hardened and precision ground surfaces, the external enveloping circle of the roller and cage assembly.The gauge is set to the raceway diameter of the mounted outer ring. This dimension is determined using a conventional internal gauge.The tapered shaft with the premounted inner ring and roller and cage assembly is then inserted in the gauge. The shaft is driven axiallyby the hydraulic method until the required radial internal clearance or preload is achieved.

Ordering example Enveloping circle gauge for cylindrical roller bearings NN3006-KOrdering designation MGA31-NN3006

Designation Design For bearings

from to

MGI21 For cylindrical roller bearings with separable inner ring

NNU4920-K NNU4948-K

NNU4920 NNU4948

MGA31 For cylindrical roller bearings with separable outer ring

NN3006-K NNU3048-K

N1006-K N1048-K



Visual inspection device In the reconditioning of wheelset bearings for rail vehicles (TAROL units), the bearing inner rings are subjected to visual examination after dismounting and cleaning. In order to check the conditionof components, a device with a light and magnifying lens is usedto visually assess the raceways, rings and all rolling elements.

Axial clearance gauge The bearing is mounted on the gauge by means of the adapter set. The dial gauge is positioned on the end face of the outer ring and set to zero. By means of an eccentric mechanism, the bearing is raised by its inner ring and the axial clearance present can be read fromthe dial gauge.

Base device The base device is suitable for all TAROL units. It comprises a frame and the measuring unit with a dial gauge.

Ordering example Axial clearance gauge for TAROL unitsOrdering designation TOOL-RAILWAY-CLEARANCE-BASIC

Bearing-specific adapter set The adapter set facilitates the precise positioning of the bearingon the base device.

Ordering example Adapter set for TAROL unit F-578116.TAROL100/175-R-TVPOrdering designation TOOL-RAILWAY-CLEARANCE.TOP-100/175



Product overview Accessories

Transport and mounting tool BEARING-MATE

000A

3317

000A

3317

Mounting paste ARCANOL-MOUNTINGPASTE

0009

F992

0009

F992

Anti-corrosion oil ARCANOL-ANTICORROSIONOIL

0009

F9A4

0009

F9A4



Accessories

Features Accessories are used to assist in the storage, transport and mounting of rolling bearings.

Transport and mounting tool The transport and mounting tool BEARING MATE, see table, isan accessory for the easy handling of medium-sized and large rolling bearings. It can also be used in the heating of bearings prior to mounting.The tool comprises two handles and two steel strips. The steel strips are tightly clamped on the outer ring of the bearing. During the transport of spherical roller bearings and self-aligning ball bearings, tilting of the inner rings is prevented by the brackets supplied.The bearing together with the tool is carried by either two peopleor by means of a crane. While it is being transported by crane,the bearing is suspended by the tool using the carrying slings and can be rotated into any position required.During heating by means of an induction heating device HEATER,the bearing can remain in the tool. It expands to the same extent as the bearing. During heating by means of an induction device with medium frequency technology, the flexible inductor must not bein direct contact with the BEARING MATE.The tool can be used for bearings up to a mass of 500 kg andat temperatures of up to +160 °C.

Available tools

Ordering example Transport and mounting tool for bearings with an outside diameter from 250 mm to 450 mm with two short brackets

Ordering designation BEARING-MATE250-450

Designation Bearing outside diameter Mass of toolmm kg

from to

BEARING-MATE250-450 250 450 6,3

BEARING-MATE450-650 450 650 6,4

BEARING-MATE650-850 650 850 6,5



Accessories

Accessories, brackets 2 long brackets to prevent tilting of the inner rings of spherical roller bearings

Ordering designation BEARING-MATE-LOCKBAR270

Accessories, pack of small parts Pack of small partsOrdering designation BEARING-MATE.SERVICE-KIT

Mounting paste The mounting paste, see table, facilitates the sliding into placeof bearing rings and prevents stick/slip effects, scoring, wear and fretting corrosion. It also gives protection against corrosion.The operating temperature range is between –30 °C and +150 °C.The paste is resistant to water, water vapour and many alkaline and acidic media.

Available mounting pastes

Anti-corrosion oil This oil gives protection of bearings that have been unpacked.It also gives long term protection against corrosion of bright metallic surfaces, for example on devices and machinery, during storage indoors.In general, it is not necessary to wash the anti-corrosion oil outof rolling bearings. It gives neutral behaviour towards conventional rolling bearing greases and oils.The oil can be removed using alkaline solvents or neutral cleaning agents.

Ordering example Spray can containing 0,4 lOrdering designation ARCANOL-ANTICORROSIONOIL-400G

Designation Container

ARCANOL-MOUNTINGPASTE-70G Tube containing 70 g

ARCANOL-MOUNTINGPASTE-250G Tube containing 250 g

ARCANOL-MOUNTINGPASTE-400G Cartridge containing 400 g

ARCANOL-MOUNTINGPASTE-1KG Can containing 1 kg


products: mounting - mogra small bearings on shaft seats, adapter sleeves or ... for the mounting of...

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